rotating equipment safety
TRANSCRIPT
-
7/27/2019 Rotating Equipment Safety
1/34
1
Rotating Equipment Safety
Working Safely and in a correct manner
-
7/27/2019 Rotating Equipment Safety
2/34
2
Introduction
A 600-m3/h centrifugal steam condensate
pump catastrophically exploded, following a
major steam system upset. Before this incident
there was a plant-wide power upset. As a
precaution to prevent backflow through the
de-energized pump, employees manually
closed the suction and discharge valves. Whenthe power was restored, the pump ran
completely isolated. When the pump
dramatically blew apart, the associated large
piping was grossly twisted and the rotor was
forced out of the electric motor. A five-pound
piece of pump casing was found over 400 feet
from the condensate pumping station. Theaccompanying photo displays the explosive
force that blew the motors rotor out of the
75-hp electric motor casing. The investigating
team established that this incident was the
result of a pump being operated with the
suction and discharge valves closed.
-
7/27/2019 Rotating Equipment Safety
3/34
3
List of EquipmentsSulphona
tionFormulation Dryer Ethoxylation F2 Soap ETP WTP
Centrifugal Pumps
Centrifugal Blowers
Lobe Pumps
Liquid ring Vacuum Pumps
Roots Blowers
Air Compressors
Thin Film Dryers
Agitators, Agitator assembly
Rotary Valves
Needler
Screw Conveyor
Belt conveyor
Sieving Machine
Granulator
Band coolers
-
7/27/2019 Rotating Equipment Safety
4/34
4
List of EquipmentsSulphonation Formulation Dryer Ethoxylation F2 Soap ETP WTP
Bagging Machine
Pallet Truck
Weighing Balance
Sewing Machine
Flaker
Metal Detector
Reciprocating pumps
Thermopac
Pressure Vessels
Cooling Towers
Neutralizer
Trident Air Dryer
High Shear Mixer
VFD
-
7/27/2019 Rotating Equipment Safety
5/34
5
List of Equipments
Sulphonation Formulation Dryer Ethoxylation F2 Soap ETP WTP
Steam Traps
Steam PCV
Finned Tube HE
Plate HE
Cyclone separators
Cooling Tower
ESP
Packed Column
Ozonator
UV system
Ion ExchangeColumn
RVD
Nauta
-
7/27/2019 Rotating Equipment Safety
6/34
6
Safety of Maintenance Personnel
Maintenance personnel should be aware of potential hazards
to reduce the risk of accidents
Safety Apparel Insulated work gloves when handling hot bearings or using
bearing heater.
Heavy work gloves when handling parts with sharp edges,especially impellers
Safety glasses (with side shields) for eye protection,especially in machine shop areas.
Steel-toed shoes for foot protection when handling pants,heavy tools, etc.
Other personal protective equipment to protect againsthazardous/toxic fluids.
-
7/27/2019 Rotating Equipment Safety
7/347
Pumps Safety
Couplings Guards: Never operate pump without a coupling guard properly installed.
Flanged Connections:
Never force piping to make a connection with a pump.
Use only fasteners of the proper size and material.
Ensure there are no missing fasteners.
Beware of corroded or loose fasteners.
Operation:
Do not operate below minimum rated flow, or with suction/discharge
valves closed.
Do not open vent or drain valves, or remove plugs while system is
pressurized.
-
7/27/2019 Rotating Equipment Safety
8/348
Pumps contd..
Maintenance Safety: Always lockout power.
Ensure pump is isolated from system and pressure is relieved
before disassembling pump, removing plugs, or disconnecting
piping.
Use proper lifting and supporting equipment to prevent
serious injury.
Observe proper decontamination procedures.
Know and follow company safety regulations.
Never apply heat to remove impeller. Observe all cautions and warnings highlighted in pump
instruction manual.
-
7/27/2019 Rotating Equipment Safety
9/349
Lobe Pump Safety
Personnel Safety
Never touch the pump or the pipelines when pumping hot liquids or whensterilising.
Never stand on the pump or pipelines.
Never run the pump with both the suction side and the pressure side
blocked.
Never put your hands or fingers inside the port connections or anywhere
close to rotating shafts.
Equipment Safety
Do not start the pump unless the seal flush has been installed & is turned
ON.
Do not install clean service or repair pump unless all power is OFF & LOCKED
OUT. Be sure pumping head is clean & free of foreign material before rotating the
shaft.
Do not close valves in inlet or discharge lines.
Use thermal expansion joints to minimize forces on pump caused thermal
expansion of piping.
Use flexible joints to limit transmission of mechanical vibration.
-
7/27/2019 Rotating Equipment Safety
10/3410
Lobe Pump Safety
Equipment Safety Do not keep operating pump without flush, which will damage seal &
pump parts due to excess heat from dry running.
Use cool, filtered flush media to obtain maximum service life of Sealcomponents & use hot media for sticky material or which solidifiesroom temperature
Do not put hands or fingers into pump body ports or drive area at anytime during operation.
Check direction of pump & drive rotation to ensure pump will rotatein proper direction.
Ensure pump & drive are lubricated
Drain product from pump prior to disconnecting the pump. Increase pump speed, use foot valve to improve priming.
Install check valve in discharge line to prevent backflow of air orfluid.
-
7/27/2019 Rotating Equipment Safety
11/3411
Centrifugal Blower
Personnel Safety
Do not touch the rotating parts when the fan is in operation. This may cause injury.Rotating parts such as couplings, pulleys, external fans, and unused shaft extensions
should be permanently guarded against accidental contact with hands or clothing.
Keep all tools, lose clothing and hands away from rotating or moving parts while the
unit is running. Never run the blower unit without the belt guard installed.
Do not touch the motor during operation or immediately after stopping. The surface is
hot and may cause a burn.
Do not use the product in explosive or corrosive environments, in the presence of
flammable gases, locations subjected to splashing water, or near combustibles. Doing
so may result in fire, electric shock or injury.
Install the fan in an enclosure in order to prevent electric shock or injury.
Disconnect the electrical power at the motor starter, fuse box or circuit breaker before
working on the system. Take special precautions to make sure the power cannot be
turned on while you are working on the blower. Use an approved Lock Out/Tag Outsystem.
Make sure the motor is electrically grounded, the mounting bolts are properly secured,
and all guards are in place before start-up.
Wear safety glasses and earplugs when working on the blower.
Do not operate blower/motor assembly with the belt guard or coupling guard removed.
Make sure to install the piping to blower inlet, before starting the blower/motor.
-
7/27/2019 Rotating Equipment Safety
12/3412
Centrifugal Blower
Equipment Safety
Do not operate blower with the outlet open to atmosphere. Connect system piping orbutterfly valve to prevent overloading the motor. Check the final installation for properamp loads.
Avoid extended exposure to machinery with high noise levels. Be sure to wear earprotective devices to reduce harmful effects to your hearing.
Do not use the fan beyond its specification, or electric shock, injury or damage toequipment may result.
Keep the area around the fan free of combustible materials in order to prevent fire or aburn.
To prevent the risk of damage to equipment, leave nothing around the fan that wouldobstruct ventilation.
When an abnormality is noted, stop the operation immediately, or fire, electric shockor injury may occur.
The motors surface temperature may exceed 70C, even under normal operatingconditions. These temperatures can cause discomfort or injury to personnel
accidentally coming into contact with hot surfaces. When installing, protection shouldbe provided to protect against accidental contact with hot surfaces to prevent bodilyinjury.
-
7/27/2019 Rotating Equipment Safety
13/3413
Coupling Guards
-
7/27/2019 Rotating Equipment Safety
14/3414
Liquid ring vacuum pump
Maintain the correct inlet fluid pressure (0.5 to 1.0 Bar) for the
better performance of the machine.
Do not keep ends open. Close it properly with plugs & caps to protect
the machine from moisture.
Ensure impeller is turning freely with hand
Do not keep the suction & discharge & the water piping dirty. Clean it
properly.
Give proper support to all piping to prevent any unwanted stress.
Do not use hard water as a sealing liquid. Use soft water to avoid
scaling inside the pipings Ensure the bearings are supplied with correct grade of grease.
-
7/27/2019 Rotating Equipment Safety
15/3415
Liquid ring vacuum pump
Inspect the motor & ensure the correct direction of rotation. If not
isolate the power & interchange any two wires.
Ensure that 2 valves are present at water inlet side. One is shut off
valve to start or stop the machine & another one is regulating valve
to control the quantity of fluid into the machine. Always open these
valves. Do not run machine in the overloaded condition. Always check the
current.
Check for excessive tightening of the gland packing. Do not keep sealing
fluid pressure in excess.
If the pump rattles at high vacuum, slightly open the vent cocks.
Check sealing liquid temperature. Excessive temperature may result in
less suction as well as vacuum.
-
7/27/2019 Rotating Equipment Safety
16/3416
Axial Flow Fans Personnel Safety
Mount a protective shield or screen, or the optional Finger Guard to the axial Faninstallation site. Do not use the Box Fan with the Finger Guard removed.
When performing any action that requires touching the blades, such as inspections,ensure that power is turned OFF. Unexpected operation of the Fan after, for example,the Fan has stopped due to contact failure or due to the operation of the overheatingprotection function (thermal protection), may result in injury.
Do not hold the Fan by its power lines, or pull the power lines with excessive force.Doing so may cause damage to the wire insulation or break the wire, resulting in injurydue to electric shock or the Fan falling.
Equipment Safety
Be sure to secure the Fan with the mounting bolts. Not doing so may result in injury due
to the Fan falling. Do not use the Fan outside the rated temperature range or above the rated voltage.
Doing so will cause the temperature of the coil (at the center of the Fan) to increase,and may result in deformation or burning of the blades.
Provide measures, such as circuit-breaker fuses, on the power supply lines of devicesthat are using Axial-flow Fans. Short-circuiting of the Fan may adversely affect otherdevices.
Do not use the Fan in locations subject to flammable or explosive gases.
Do not attempt to disassemble, repair, or modify the Fan. A precision-type ball bearing is used to hold the shaft of the Fan. Ensure that the Fan isnot subjected to shock, such as falling, otherwise the service life and performancecharacteristics of the Fan will be adversely affected.
Do not wire the power lines of the Fan in series with those of other Fans or devices.Doing so may cause a voltage above the Fan's rated voltage to be applied, and this mayresult in malfunction or burning. Be sure to wire devices in parallel.
-
7/27/2019 Rotating Equipment Safety
17/3417
Roots Blowers
Personnel Safety
Keep fingers and clothing away from blower inlet and discharge ports,revolving belts, pulleys, drive coupling etc.
Do not use the air discharge from this unit for breathing not suitable forhuman consumption.
Do not loosen or remove the oil filter plug, drain plugs, covers or break anyconnections, etc., in the blower air or oil system until the unit is shut downand the air pressure has been relieved.
Electric shock can and may be fatal. Open main, disconnect switch, tag and lockout before working on thecontrol.
Disconnect the Blower unit from its power source, tag and lockout beforeworking on the unit.
Stop the unit if any repairs or adjustments on or around the Blower arerequired.
Equipment Safety Do not operate unit if safety devices are not operating properly. Check
periodically. Avoid bypassing safety devices.
No attempt should ever be made to control the capacity of compressor bymeans of throttle valves in the intake or discharge piping. This increases thepower load on the motor and may seriously damage the compressor.
-
7/27/2019 Rotating Equipment Safety
18/3418
Roots Blowers
Equipment Safety Over tightened belts leads to heavy bearing loads and shaft
deflections and may result in premature failure of bearings / shafts.
Piping should be supported near the compressor to eliminate deadweight strains on the blower. A flexible pipe bellow isrecommended in the discharge pipeline, close to the compressordischarge, so as to isolate compressor and pipeline vibrations.
Choking of suction filter leads to increased load on the blower.Replace filter every three months. Servicing the air filters is one ofthe most important maintenance operations to be performedperiodically to ensure long blower life.
Relief valves should be placed as close as possible to the Blowerdischarge. They are not meant to discharge full capacity and
therefore cannot be taken as safeguard against total blockage.
Ensure lubrication of bearings and gears is regularly maintained.This avoids premature failure of Blower.
Provide suitable protection/cover to prevent lubricant gettingcontaminated by dust, dirt and water as these render it ineffective.
-
7/27/2019 Rotating Equipment Safety
19/3419
Pump Case study -1
In an abandoned unit, a pump that handled a 50% solution ofcaustic soda was isolated by closing both valves.
A contractor was asked to switch on a ventilation fan for the
nearby area. The switch for the fan was close to that for the
pump and the labels were small The contractor switched on the caustic pump in error.
The pump ran between closed valves and
overheated. There was a loud boom, which
rattled windows 60 m away. The pump wasdamaged and dislodged from its base plate.
-
7/27/2019 Rotating Equipment Safety
20/3420
Pump Case study -Discussion
The incident would not have occurred if
The pump had been drained.
The pump had been defused
The switches were near the equipment theyserved. (Emergency switches can be away)
The labels were easy to read
Someone familiar with the unit was asked to
start the distillation fan
-
7/27/2019 Rotating Equipment Safety
21/3421
Can this happen at Galaxy?
A reciprocating compressor was started up in error with the delivery valve closed.
The relief valve was too small and the packing round the cylinder rod was blown
out.
The relief valve in this case was merely a sentinel (safeguard) to
warn the operator and was not capable of passing the full out put of
the compressor
A reciprocating pump was ordered that was capable of delivering 2 m3/h. The
manufacturer supplied his nearest standard size, which was capable of delivering
3 m3/h, but sized a relief valve for 2 m3/h.
When the pump was operated against a restricted delivery, the
coupling rod was bent. Fortunately , it was the weakest part of the
system. A relief valve, supplied with a compressor , was of an unsuitable type, and was
mounted horizontally and vibrated so much that the springs dented the casing.
Relief valves should be mounted vertically so that any condensation
or dirt collects in them has the maximum chance of falling out.
-
7/27/2019 Rotating Equipment Safety
22/3422
Rotary Valve
Personnel Safety Do not attempt to work on, clean or service an airlock, or open or
remove any protective cover, guard, grate or maintenance paneluntil the POWER has been turned off and LOCKED OUT, and thevalve has come to a complete stop.
Never place hands or fingers in an airlock, unless it has beendisconnected and locked out, and a wooden block has been placedin the valve to prevent the rotor from turning.
Do not manually override or electrically bypass any protectivedevice.
Do not connect power to or operate an valve unless all moving partsare covered and all covers, guards, grates, and maintenance panelsare in place and securely fastened.
Do not attempt to start an valve when loaded.
Never place any part of your body under or near rotating membersor moving parts of an airlock.
Rotating members and moving parts must be completely enclosedbefore connecting power and before operation.
Keep away from an valve when it is running.
-
7/27/2019 Rotating Equipment Safety
23/3423
Rotary Valve
Personnel Safety Use personal protective equipment when and where appropriate,
such as hard hats, helmets, gloves, earplugs, and eye protectiondevices.
Keep personal protective equipment in good repair and convenientto the operator.
High voltage and rotating parts can cause serious or fatal injury.
Only qualified, trained, and experienced personnel should performinstallation, operation and maintenance of electrical machinery.
Make sure that the motor and the frame of each valve is effectivelygrounded in accordance with OSHA safety and health standards, theNational Electrical Code and local codes.
All protective covers, guards, grates, maintenance panels, switchesand warning decals must be kept in place and in good repair. Any
valve with a damaged, malfunctioning, defective, or missingprotective device must be taken out of service until the protectivedevice can be repaired or replaced.
All valve inlet and discharge openings must be completely enclosedto prevent human access when valve is operating, and must remainenclosed until POWER IS TURNED OFF AND LOCKED OUT.
-
7/27/2019 Rotating Equipment Safety
24/3424
Rotary Valve
Equipment Safety
A valve must be equipped with a properly functioning Protective
Interlocking Electrical Control Switch (PCS), a Padlockable Manual Power
Lockout Switch, and with the other basic safety equipment listed above.
On-off, interlock and padlock functions of the PCS must be tested and
logged daily by supervisory personnel.
Keep the workplace cleaned up and free of dirt and dust at all times.
Do not attempt to work on slippery or unsafe ladders or work platforms
when maintenance or repair work is being performed on an airlock.
Do not climb on ladders or work on platforms unless maximum load rating is
posted.
Do not exceed maximum load ratings when installing or servicing an airlock.
Never allow any kind of metal or other foreign objects to enter an airlock. Any valve that is used in the processing of explosive materials in hazardous
environments requires an evaluation on the part of the user and operator of
proper and adequate valve monitoring equipment, dust control, explosion
relief venting, and electrical equipment enclosures.
-
7/27/2019 Rotating Equipment Safety
25/34
25
Thin Film Dryer
Personnel Safety
Do not allow person to operate the machine unless they have carefully readand understood the operating procedure of equipment.
Never insert body parts or foreign objects into the running machine. Keep
fingers Hands, Feets, Tools, Rods, Sticks or any other foreign parts away
from moving parts while machine is running condition.
Do not touch rotating parts when machine is in running condition, this may
cause injury. Rotating parts such as coupling pulley, belt should bepermanently guarded against accident contact with hand or clothes.
Do not touch the motor during operation or immediately after stopping. The
surface is hot and may cause a burn.
Take precaution to remove the fuse during maintenance work in machine.
Equipment Safety Make sure the motor is properly earthed. Make sure that the direction of the dryer blade it must be clockwise when
see at the top of dryer.
After shut down first check the motor rotation it must be clockwise whensee at the top.
-
7/27/2019 Rotating Equipment Safety
26/34
26
Thin Film Dryer
Equipment Safety
Make sure dryer current is within limit. No load current = 60-80Amp, On load current = 100-130 Amp.
When dryer current is high automatically in running condition
immediately inform to maintenance person -it may be cause of
blades detached from the ring.
Make sure that the Gear box temperature is on limit (60-90c)otherwise due to high temperature gear box will be damage.
Keep the area around the machine free of combustibles material in
order of prevent fire or burn.
When abnormality is noted (high vibration, high sound) stop the
machine immediately otherwise electric shock, fire, injury may
occur.
Make sure the bush cooling water supply is proper (20 drops/ min)
otherwise the temp of bush is high & due to friction possibility of
fire is there.
-
7/27/2019 Rotating Equipment Safety
27/34
27
Granulator
Personnel Safety
Never insert body parts or foreign objects into the running machine. Keep
fingers, hands, arms, feet, tools, rods, sticks or any other foreign objects
clear of moving parts when running the machine.
Make sure the motor is electrically grounded, the mounting bolts are properly
secured and all guards are in place before start up.
Disconnect machine and lock out power before opening, adjusting, cleaning,
servicing and changing screens, impellers, guards or any other parts.
Appropriate care must be taken when handling perforated screens which
have holes that break out on edges of the screen flange.
Wear proper apparel. Do not wear loose clothing, gloves, neckties, rings,
bracelets or other jewelry which may get caught in the machine.
Always use safety glasses when operating the machine. Use mask if operation
is dusty.
-
7/27/2019 Rotating Equipment Safety
28/34
28
Granulator
Equipment Safety
Check the direction of rotation of impeller it must be clockwise direction
when viewed from above the machine.
Do not start machine under load. Or empty condition.
Stop machine immediately if the impeller is heard rubbing or ticking.
At the time of tripping call electrician for resetting the granulator.
Do not allow high moisture in feed so as to avoid tripping. Keep the area around granulator free of combustible material in order to
prevent fire or burn.
Before trying operation with different screen and impeller combinations
check the Gap adjustment between impeller and screen.
Inspect interlock switches and cables regularly. Replace if damaged or
defective. Ensure that interlock switches are working correctly prior to usingthe machine. Do not disable any interlock switch.
-
7/27/2019 Rotating Equipment Safety
29/34
29
Needler Personnel Safety
Do not touch rotating parts when needler is in running condition, this may
cause injury. Rotating part such as coupling guard, pulley belt should beguarded against accident contact with hand or clothes.
Keep all tools, loose clothing and hand away from rotating part.
Check the direction of motor it must be in clockwise direction.
Check the direction of needler plodder while looking at it from the extrusion
end. The Right side worm must rotate in anticlockwise
direction and the Left side worm must rotate in clockwise direction. Equipment Safety
Ensure the air supply is on, starts motor of needler after making sure thatthe clutch is disengaged switch on the clutch and operate the needlerthrough push button provided on the operation console.
Ensure that mass feed to the needler is free from any extraneous/ hardmaterial. Never allow foreign material except SLS powder as it will damage
barrel and warm. Ensure that the temperature of extrusion plate is not exceeding 70C.
Do not circulate the water initially in needler jacket. Once the SLS powderhas reached the barrel, water should be started now.
Regulate the flow of water through the barrels by operating the relevantvalve on the inlet and maintain uniform water supply.
At the time of needler stoppage water supply should be closed condition.
-
7/27/2019 Rotating Equipment Safety
30/34
30
Needler At the time of die plate chock up take dryer material outside of needler, stop
needler, remove entire material from hopper, fix new die plate, take
approximate 25 Kg material in hopper and then start the needler. If dryer is stopped more then half hour change the die plate of needler.
After every 4000 hours of operation of the needler change the oil in main gear
box and bearing housing.
After every 200 hours, lubricate the drive shaft by injecting grease in to the
grease nipple provided on bearing housing.
Ensure that the transmission belts (V belt) are correctly stretched. If necessaryadjust the tension using relevant stretcher.
When abnormality is noted (abnormal sound, high vibration) stop the machine
immediately otherwise electric shock, fire, injury may occur.
Keep the area around the machine free of combustibles material in order of
prevent fire or burn.
Make sure needler current within limit. No load current = 25 Amp, on load
current = 30-45 Amp.
If needler current is continuous increases in running condition, stop needler,
remove entire material from hopper, fix the die plate then start the needler.
-
7/27/2019 Rotating Equipment Safety
31/34
31
Mixers and Agitators Equipment Safety
Rotate mixer shaft by hand to check shaft straightness and assure that the impeller is
free of any obstructions in the tank. The impeller rotates in the direction shown in the assembly drawing. Opposite rotation
may cause overload and inefficient mixing.
Vortexing may occur if liquid level is too close to the upper impeller. This will cause
aeration of the product and excessive vibration of the equipment.
When mixing products of dissimilar viscosities and/or specific gravities the lighter or
less viscous material should be introduced first. Gradually add the heavier material or
powders into the center of the tank while the agitator is running.
Never dump large amounts of powder or solids into the mixing tank. This may create
clotting or sanding in of impeller and cause damage to the equipment.
Do not start mixer with impeller buried in solids or with liquid solution solidified.
Damage will occur.
If impeller is buried in solids prior to starting mixer, solids must be dispersed. This may
be achieved with an air hose, a recirculating pump, or a large stirring stick if necessary(depending on tank size).
-
7/27/2019 Rotating Equipment Safety
32/34
32
Mixers and Agitators
Equipment Safety Check gearbox lubrication level. Some models may be shipped "dry"
(without lubricant) and must be filled with the proper lubricantbefore startup.
Check the oil level before start up. Verify that none was lost duringshipment/installation. Do not over or under fill the gearbox.
Shaft seal must be lubricated/flushed during operation of mixer.
Extended operation of mixer when liquid level is at or near bottom
impeller is not recommended. Excessive loading and vibration willoccur.
Keep motors free from oil, dust, dirt, water, and chemicals. Keepair intakes and outlets free from foreign material.
Personnel Safety Always lockout power before installing or removing mixer
equipment High voltage and rotating parts can cause serious or fatal injury.
Electric machinery can be hazardous. Installation, operation, andmaintenance of electric machinery should be performed byqualified personnel.
-
7/27/2019 Rotating Equipment Safety
33/34
33
Safety Measure Strategy
-
7/27/2019 Rotating Equipment Safety
34/34
Machinery Hazard Prevention
Spatial separation between human and
machine work spaces
Isolation principle: Safety protection like guards
Temporal separation
Stoppage principle: Safety protection like interlocking devices
Human
Workspace
Machine
WorkspaceHAZARD ZONE